EP4460533A1

EP4460533A1 - Polycarbonate copolymer compositions

Info

Publication number: EP4460533A1
Application number: EP23702666.1A
Authority: EP
Inventors: Fabio Di Lena; Mark Adrianus Johannes van der Mee; Roland Sebastian Assink
Original assignee: SHPP Global Technologies BV
Current assignee: SHPP Global Technologies BV
Priority date: 2022-01-07
Filing date: 2023-01-06
Publication date: 2024-11-13
Also published as: WO2023131909A1; KR20240127467A; CN118510828A

Abstract

A polycarbonate composition, including 10-80 weight percent (wt%) of a homopolycarbonate, a poly(phthalate-carbonate), or a combination thereof; 10-30 wt% of a bromine-containing polycarbonate copolymer; 5-60 wt% of a poly(carbonate-siloxane), present in an amount effective to provide 1-10 wt% of total siloxane, based on the total weight of the polycarbonate composition; 5-30 wt% of a glass-containing reinforcing agent; optionally, up to 10 wt% of a mineral filler; optionally, an organophosphorous flame retardant in amount effective to provide up to 1.5 wt% of phosphorous, based on the total weight of the polycarbonate composition; and optionally, up to 10 wt% of an additive, wherein the amount of homopolycarbonate, poly(phthalate-carbonate, bromine-containing polycarbonate copolymer, poly(carbonate-siloxane), glass-containing reinforcing agent, optional mineral filler, optional organophosphorous flame retardant, and optional additive total 100 wt%.

Description

POLYCARBONATE COPOLYMER COMPOSITIONS

CROSS REFERENCE TO RELATED APPLICATION

This PCT application claims priority to European Application No. 22150546.4, filed January 7, 2022, the content of which is herein incorporated by reference in its entirety.

BACKGROUND

[0001] The harmonized fire standard for rail applications, EN-45545, imposes stringent requirements on heat release, smoke density, and toxicity and flame spread properties allowed for materials used in rail applications in the European Union.

[0002] As set-forth in the requirements of EN-45545, “Hazard Levels” (HL1 to HL3) have been designated, reflecting the degree of probability of personal injury as the result of a fire. The levels are based on dwell time and are related to operation and design categories. HL1 is the lowest hazard level and is typically applicable to vehicles that run under relatively safe conditions (easy evacuation of the vehicle). HL3 is the highest hazard level and represents most dangerous operation/design categories (difficult and/or time-consuming evacuation of the vehicle, e.g., in underground rail cars). EN-45545 classifies products are classified into 26 requirements sets (R1-R26). R1 includes horizontal and vertical interior surfaces and R6 includes passenger seat shell and coverings. For each product type, different test requirements for the hazard levels are defined.

[0003] Polycarbonates are useful in the manufacture of articles and components for a wide range of applications, from automotive parts to electronic appliances. Because of their broad use, particularly in rail interiors, it is desirable to provide polycarbonate compositions with properties that meet or exceed the requirements set-forth under EN-45545. However, it is particularly challenging to manufacture articles that meet the requirements of EN-45545 and that have good mechanical properties, including high stiffness, high strength, good impact strength, and/or good processability.

[0004] Accordingly, there remains a need for polycarbonate compositions that have a combination of properties, including lower smoke density, lower heat release, improved critical heat flux at extinguishment, and/or low flame spread properties. It would be a further advantage if the polycarbonate compositions could be made at a low material cost, with manufacturing ease, and with desirable mechanical properties.

SUMMARY

[0005] Provided is a polycarbonate composition including 10 to 80 weight percent (wt%), or 20 to 75 wt%, or 35 to 70 wt% of a homopolycarbonate, a poly(phthalate-carbonate), or a combination thereof; 10 to 30 wt%, or 10 to 25 wt% of a bromine-containing polycarbonate copolymer; 5 to 60 wt%, or 10 to 60 wt% of a poly(carbonate-siloxane), present in an amount effective to provide 1 to 10 wt% of total siloxane, based on the total weight of the polycarbonate composition; 5 to 30 wt% of a glasscontaining reinforcing agent; optionally, up to 10 wt% of a mineral filler, preferably wherein the mineral filler comprises talc, kaolin, calcium silicate, calcinated kaolin, calcium carbonate, wollastonite, or a combination thereof; optionally, an organophosphorous flame retardant in amount effective to provide up to 1.5 wt% of phosphorous, based on the total weight of the polycarbonate composition; and optionally, up to 10 wt% of an additive, wherein the amount of homopolycarbonate, poly(phthalate-carbonate, bromine-containing polycarbonate copolymer, poly(carbonate-siloxane), glass-containing reinforcing agent, optional mineral filler, optional organophosphorous flame retardant, and optional additive total 100 wt%.

[0006] Also provided is an article including the polycarbonate composition, preferably wherein the article is a railway component, preferably an interior railway component, more preferably wherein the article comprises a seat component, an extruded interior cladding, a molded interior cladding, a side wall, a front wall, an end wall, a partition, a room divider, a flap, a box, a hood, a louvre, a ceiling panel, a table tray, a head rest, a privacy divider, a center console, an arm rest, a leg rest, a food tray, an end bay, a shroud, a kick panel, a foot well, literature pocket, a monitor, a bezel, a line replaceable unit, a foot bar, a luggage rack, a luggage container, a luggage compartment, a floor composite, a wall composite, an air duct, a strip, a device for passenger information, a window frame, an interior lining, an interior vertical surface, an interior door, a lining for an internal door, a lining for an external door, an interior horizontal surface, an electrical component, or a lighting component. Further provided is a method for forming the article, wherein the method includes molding, casting, or extruding the polycarbonate composition.

DETAILED DESCRIPTION

[0007] The inventors hereof have discovered polycarbonate compositions having low smoke density characteristics (DS-4, measured according to ISO5659-2), low heat release characteristics (MAHRE, measured according to ISO5660-1), improved integral of smoke density as a function of time (VOF4, measured according to ISO5659-2), and/or an improved critical heat flux at extinguishment (CFE, measured according to ISO 5658-2).

[0008] It is exceptionally challenging to manufacture materials that meet stringent smoke density standards, heat release standards, and/or flame spread standards in addition to meeting or exceeding other material requirements while also providing a low material cost, manufacturing ease, and good mechanical properties. Advantageously, the inventors have discovered that compositions including a homopolycarbonate, poly(carbonate-siloxane), bromo-substituted polycarbonate copolymer, and glasscontaining reinforcing agent provide the desired smoke density and heat release characteristics while also providing good stiffness and impact. This was a surprising and unexpected because high loadings of inorganic fillers like glass or minerals typically will result in improved fire properties at the expense of impact properties, processability, and/or color capability. However, the inventors discovered that the combination of a homopolycarbonate, a poly(phthalate-carbonate), or a combination thereof, a poly(carbonate-siloxane), a bromo-substituted polycarbonate copolymer, and a glass-containing reinforcing agent resulted in robust smoke density and heat release meeting R6-HL2 and retaining impact properties.

[0009] In a particularly advantageous feature, the polycarbonate compositions may have a smoke density after 4 minutes (DS-4) of 300 or less, measured in accordance with ISO 5659-2 on a 3 mm thick plaque at 50 kW/m²; an integral of smoke density as a function of time after 4 minutes (VOF4) of 600 or less, measured in accordance with ISO 5659-2 on a 3 mm thick plaque at 50 kW/m²; a maximum average heat release (MAHRE) of 90 kW/m² or less, measured in accordance with ISO 5660-1 on a 3 mm thick plaque at 50 kW/m²; a critical heat flux at extinguishment (CFE) of 20 kW/m² or greater, measured in accordance with ISO 5658-2 on a 3 mm thick plaque; or a combination thereof. Typically, the polycarbonate compositions have a smoke density after 4 minutes (DS-4) of 300 or less, measured in accordance with ISO 5659-2 on a 3 mm thick plaque at 50 kW/m²; an integral of smoke density as a function of time after 4 minutes (VOF4) of 600 or less, measured in accordance with ISO 5659-2 on a 3 mm thick plaque at 50 kW/m²; a maximum average heat release (MAHRE) of 90 kW/m² or less, measured in accordance with ISO 5660-1 on a 3 mm thick plaque at 50 kW/m²; a critical heat flux at extinguishment (CFE) of 20 kW/m²or greater, measured in accordance with ISO 5658-2 on a 3 mm thick plaque; or a combination thereof. In some aspects, the polycarbonate composition can have each of these properties at the same time.

[0010] The polycarbonate compositions include 10 to 80 weight percent (wt%), or 20 to 75 wt%, or 35 to 70 wt% of a homopolycarbonate, a poly(phthalate-carbonate), or a combination thereof; 10 to 30 wt%, or 10 to 25 wt% of a bromine-containing polycarbonate copolymer; 5 to 60 wt%, or 10 to 60 wt% of a poly(carbonate-siloxane); and 5 to 30 wt% of a glass-containing reinforcing agent.

[0011] The term “polycarbonate” as used herein means a polymer or copolymer having repeating structural carbonate units of formula (1) wherein at least 60% of the total number of R¹ groups contain aromatic moieties and the balance thereof are aliphatic, alicyclic, or aromatic. In one or more aspects, each R¹ is a Ce-3o aromatic group. R¹ may be derived from an aromatic dihydroxy compound of the formula HO-R '-OH, in particular of formula (2) HO-A'-Y'-A^OH (2) wherein each of A¹ and A² is a monocyclic divalent aromatic group and Y¹ is a single bond or a bridging group having one or more atoms that separate A¹ from A². In one or more aspects, one atom separates A¹ from A². Preferably, each R¹ may be derived from a bisphenol of formula (3) wherein R^a and R^b are each independently a halogen, C1-12 alkoxy, or C1-12 alkyl, and p and q are each independently integers of 0 to 4. It will be understood that when p or q is less than 4, the valence of each carbon of the ring is filled by hydrogen. X^a is a bridging group connecting the two hydroxy-substituted aromatic groups, where the bridging group and the hydroxy substituent of each Ce arylene group are disposed ortho, meta, or para (preferably para) to each other on the Ce arylene group. In one or more aspects, the bridging group X^a is single bond, -O-, -S-, -S(O)-, -S(O)2-, -C(O)-, or a Ci-eo organic group. The organic bridging group may be cyclic or acyclic, aromatic or non-aromatic, and may further comprise heteroatoms such as halogens, oxygen, nitrogen, sulfur, silicon, or phosphorous. The i.go organic group may be disposed such that the Cg arylene groups connected thereto are each connected to a common alkylidene carbon or to different carbons of the Ci-go organic bridging group. In one or more aspects, p and q is each 1, and R^a and R^b are each a C1-3 alkyl group, preferably methyl, disposed meta to the hydroxy group on each arylene group.

[0012] Other exemplary dihydroxy compounds of the formula HO-R -OH include aromatic dihydroxy compounds of formula (4) wherein each R^h is independently a halogen atom, Ci-io hydrocarbyl group such as a Ci-io alkyl, a halo- substituted Ci-io alkyl, a CMO aryl, or a halo-substituted Cg-io aryl, and n is 0 to 4.

[0013] Exemplary dihydroxy compounds include, but are not limited to, 4, 4'-dihydroxy diphenyl, 1,6-dihydroxynaphthalene, 2,6-dihydroxynaphthalene, bis(4-hydroxyphenyl)methane, bis(4- hydroxyphenyl)diphenylmethane, bis(4-hydroxyphenyl)- 1 -naphthylmethane, 1 ,2-bis(4- hydroxyphenyl)ethane, l,l-bis(4-hydroxyphenyl)-l -phenylethane, 2-(4-hydroxyphenyl)-2-(3- hydroxyphenyl)propane, bis(4-hydroxyphenyl)phenylmethane, 2,2-bis(4-hydroxy-3- bromophenyl)propane, 1,1 -bis (hydroxyphenyl)cyclopentane, l,l-bis(4-hydroxyphenyl)cyclohexane, 1,1- bis(4-hydroxyphenyl)isobutene, 1, l-bis(4-hydroxyphenyl)cyclododecane, trans-2,3-bis(4- hydroxyphenyl)-2-butene, 2,2-bis(4-hydroxyphenyl)adamantane, alpha, alpha' -bis(4- hydroxyphenyl)toluene, bis(4-hydroxyphenyl)acetonitrile, 2,2-bis(3-methyl-4-hydroxyphenyl)propane, 2,2-bis(3-ethyl-4-hydroxyphenyl)propane, 2,2-bis(3-n-propyl-4-hydroxyphenyl)propane, 2,2-bis(3- isopropyl-4-hydroxyphenyl)propane, 2,2-bis(3-sec-butyl-4-hydroxyphenyl)propane, 2,2-bis(3-t-butyl-4- hydroxyphenyl)propane, 2,2-bis(3-cyclohexyl-4-hydroxyphenyl)propane, 2,2-bis(3-allyl-4- hydroxyphenyl)propane, 2,2-bis(3-methoxy-4-hydroxyphenyl)propane, 2,2-bis(4- hydroxyphenyl)hexafluoropropane, 1 , 1 -dichloro-2,2-bis(4-hydroxyphenyl)ethylene, 1 , 1 -dibromo-2,2- bis(4-hydroxyphenyl)ethylene, 1, l-dichloro-2,2-bis(5-phenoxy-4-hydroxyphenyl)ethylene, 4,4'- dihydroxybenzophenone, 3,3-bis(4-hydroxyphenyl)-2-butanone, l,6-bis(4-hydroxyphenyl)-l,6- hexanedione, ethylene glycol bis(4-hydroxyphenyl)ether, bis(4-hydroxyphenyl)ether, bis(4- hydroxyphenyl)sulfide, bis(4-hydroxyphenyl)sulfoxide, bis(4-hydroxyphenyl)sulfone, 9,9-bis(4- hydroxyphenyl)fluorine, 2,7-dihydroxypyrene, 6,6'-dihydroxy-3,3,3',3'- tetramethylspiro(bis)indane ("spirobiindane bisphenol"), 3,3-bis(4-hydroxyphenyl)phthalimide, 2,6-dihydroxydibenzo-p-dioxin, 2,6- dihydroxythianthrene, 2,7-dihydroxyphenoxathin, 2,7-dihydroxy-9,10-dimethylphenazine, 3,6- dihydroxydibenzofuran, 3,6-dihydroxydibenzothiophene, and 2,7-dihydroxycarbazole, resorcinol, substituted resorcinol compounds such as 5-methyl resorcinol, 5-ethyl resorcinol, 5-propyl resorcinol, 5- butyl resorcinol, 5-t-butyl resorcinol, 5-phenyl resorcinol, 5-cumyl resorcinol, 2,4,5,6-tetrafluoro resorcinol, 2,4,5,6-tetrabromo resorcinol, or the like; catechol; hydroquinone; substituted hydroquinones such as 2-methyl hydroquinone, 2-ethyl hydroquinone, 2-propyl hydroquinone, 2-butyl hydroquinone, 2- t-butyl hydroquinone, 2-phenyl hydroquinone, 2-cumyl hydroquinone, 2,3,5,6-tetramethyl hydroquinone, 2,3,5,6-tetra-t-butyl hydroquinone, 2,3,5,6-tetrafluoro hydroquinone, 2,3,5,6-tetrabromo hydroquinone, or the like, or a combination thereof.

[0014] Specific examples of bisphenol compounds of formula (3) include l,l-bis(4- hydroxyphenyl) methane, l,l-bis(4-hydroxyphenyl) ethane, 2,2-bis(4-hydroxyphenyl) propane (“bisphenol-A” or “BPA”), 2,2-bis(4-hydroxyphenyl) butane, 2,2-bis(4-hydroxyphenyl) octane, 1,1- bis(4-hydroxyphenyl) propane, l,l-bis(4-hydroxyphenyl) n-butane, 2,2-bis(4-hydroxy-2-methylphenyl) propane, l,l-bis(4-hydroxy-t-butylphenyl) propane, 3,3-bis(4-hydroxyphenyl) phthalimidine, 2-phenyl- 3,3-bis(4-hydroxyphenyl) phthalimidine (PPPBP), l,l-bis(4-hydroxy-3-methylphenyl)cyclohexane (DMBPC), or a combination thereof.

[0015] The polycarbonates may have an intrinsic viscosity, as determined in chloroform at 25°C, of 0.3 to 1.5 deciliters per gram (dL/g), preferably 0.45 to 1.0 dL/g. The polycarbonates may have a weight average molecular weight (Mw) of 10,000 to 200,000 grams per mole (g/mol), preferably 20,000 to 100,000 g/mol, as measured by gel permeation chromatography (GPC), using a crosslinked styrene-divinylbenzene column using polystyrene standards and calculated for polycarbonate. GPC samples are prepared at a concentration of 1 mg/mL, and are eluted at a flow rate of 1.5 mL/min.

[0016] The polycarbonate compositions of the present disclosure include a homopolycarbonate (wherein each R¹ in the polymer is the same). In one or more aspects, the homopolycarbonate in the polycarbonate composition is derived from a bisphenol of formula (2), preferably bisphenol A, in which each of A¹ and A² is p-phenylene and Y¹ is isopropylidene in formula (2).

[0017] For example, in some aspects, the homopolycarbonate is a bisphenol A homopolycarbonate. The bisphenol A homopolycarbonate may have a melt flow rate (MFR) of 3 to 50, per 10 min at 300°C and a 1.2-kilogram (kg) load and a Mw of 17,000 to 40,000 g/mol, or 20,000 to 30,000 g/mol, or 21,000 to 23,0000 g/mol, each as measured as described above. In some aspects, the homopolycarbonate comprises a linear bisphenol A homopolycarbonate. In some aspects, the homopolycarbonate comprises a linear bisphenol A homopolycarbonate having a Mw of 26,000 to 40,000 g/mol, or 27,000 to 35,000 g/mol, as determined by GPC using polystyrene standards and calculated for polycarbonate; or a linear bisphenol A homopolycarbonate having a Mw of 15,000 to 25,000 g/mol, or 17,000 to 25,000 g/mol, as determined by GPC using polystyrene standards and calculated for polycarbonate; or a combination thereof.

[0018] “Polycarbonates” include homopolycarbonates (wherein each R¹ in the polymer is the same) and copolymers comprising different R¹ moieties in the carbonate (“copolycarbonates”), and copolymers comprising carbonate units and other types of polymer units, such as ester units or siloxane units.

[0019] The certain polycarbonate of the polycarbonate compositions may include an aromatic poly(ester-carbonate). Such polycarbonates further contain, in addition to recurring carbonate units of formula (1), repeating ester units of formula (5) O O

- C - T - C - O - J - O - wherein J is a divalent group derived from an aromatic dihydroxy compound (including a reactive derivative thereof), such as a dihydroxy compound of formula (2), e.g., bisphenol A; and T is a divalent group derived from an aromatic dicarboxylic acid (including a reactive derivative thereof), preferably isophthalic or terephthalic acid wherein the weight ratio of isophthalic acid to terephthalic acid is 91:9 to 2:98. Copolyesters containing a combination of different T or J groups may be used. The polyester units may be branched or linear.

[0020] In another aspect, J is derived from an aromatic dihydroxy compound, e.g., resorcinol. A portion of the groups J, for example up to 20 mole percent (mol%) may be a C2-30 alkylene group having a straight chain, branched chain, or cyclic (including polycyclic) structure, for example ethylene, n- propylene, i-proplyene, 1,4-butylene, 1,4-cyclohexylene, or 1,4-methylenecyclohexane. Preferably, all J groups are aromatic.

[0021] Aromatic dicarboxylic acids that may be used to prepare the polyester units include isophthalic or terephthalic acid, l,2-di(p-carboxyphenyl)ethane, 4,4'-dicarboxydiphenyl ether, 4,4'- bisbenzoic acid, or a combination thereof. Acids containing fused rings may also be present, such as in 1,4-, 1,5-, or 2,6-naphthalenedicarboxylic acids. Specific dicarboxylic acids include terephthalic acid, isophthalic acid, naphthalene dicarboxylic acid, or a combination thereof. A specific dicarboxylic acid comprises a combination of isophthalic acid and terephthalic acid wherein the weight ratio of isophthalic acid to terephthalic acid is 91:9 to 2:98. A portion of the groups T, for example up to 20 mol%, may be aliphatic, for example derived from 1,4-cyclohexane dicarboxylic acid. Preferably all T groups are aromatic. The molar ratio of ester units to carbonate units in the polycarbonates may be, for example, 1:99 to 99: 1, or 10:90 to 90: 10, or 25:75 to 75:25, or 2:98 to 15:85, depending on the desired properties of the final composition.

[0022] The polycarbonate compositions may include a poly(ester-carbonate) including bisphenol A carbonate units and isophthalate/terephthalate -bisphenol A ester units, i.e., a poly(bisphenol A carbonate)-co-(bisphenol A-phthalate-ester) of formula (6a): wherein x and y represent the mole fraction of bisphenol A carbonate units and isophthalate/terephthalate -bisphenol A ester units, respectively. Generally, the units are present as blocks. In one or more aspects, the mole ratio of carbonate units x to ester units y in the polycarbonates is 1:99 to 50:50, or 5:95 to 25:75, or 10:90 to 45:55. Copolymers of formula (5) comprising 35-45 wt% of carbonate units and 55-65 wt% of ester units, wherein the ester units have a molar ratio of isophthalate to terephthalate of 45:55 to 55:45 are often referred to as poly(carbonate-ester)s. Copolymers comprising 15-25 wt% of carbonate units and 75-85 wt% of ester units, wherein the ester units have a molar ratio of isophthalate to terephthalate from 98:2 to 88:12, are often referred to as poly(phthalate-carbonate)s and may optionally be present in the polycarbonate compositions. [0023] In another aspect, the poly(ester-carbonate) may be a poly(carbonate-co-monoarylate ester) of formula (6b) that includes aromatic carbonate units (1) and repeating monoarylate ester units wherein R¹ is as defined in formula (1), and each R^h is independently a halogen atom, a CMO hydrocarbyl such as a Ci-io alkyl group, a halogen-substituted Ci-io alkyl group, a Ce-io aryl group, or a halogensubstituted Ce-io aryl group, and n is 0-4. Preferably, each R^h is independently a Cu alkyl, and n is 0-3, 0- 1, or 0. The mole ratio of carbonate units x to ester units z may be 99: 1 to 1:99, or 98:2 to 2:98, or 90: 10 to 10:90, or 50:50 to 99:1, or 1:99 to 50:50.

[0024] In one or more aspects, the poly(ester-carbonate) comprises aromatic ester units and monoarylate ester units derived from the reaction of a combination of isophthalic and terephthalic diacids (or a reactive derivative thereof) with resorcinol (or a reactive derivative thereof) to provide isophthalate/terephthalate -resorcinol (“ITR” ester units). The ITR ester units may be present in the high heat poly(ester-carbonate) in an amount greater than or equal to 95 mol%, preferably greater than or equal to 99 mol% or greater than or equal to 99.5 mol%, based on the total moles of ester units in the polycarbonate. A preferred high heat poly(ester-carbonate) comprises bisphenol A carbonate units, and ITR ester units derived from terephthalic acid, isophthalic acid, and resorcinol, i.e., a poly(bisphenol A carbonate-co-isophthalate/terephthalate -resorcinol ester) of formula (6c) wherein the mole ratio of x:z is 98:2 to 2:98, or 90: 10 to 10:90, or 50:50 to 99: 1, or 1:99 to 50:50. The ITR ester units may be present in the poly(bisphenol A carbonate-co-isophthalate-terephthalate-resorcinol ester) in an amount greater than or equal to 95 mol%, preferably greater than or equal to 99 mol% or greater than or equal to 99.5 mol%, based on the total moles of ester units in the copolymer. Other carbonate units, other ester units, or a combination thereof may be present, in a total amount of 1 to 20 mole%, based on the total moles of units in the copolymers, for example bisphenol ester units of formula (5 a) and monoaryl carbonate units of formula (7): wherein each R^h is independently a CMO hydrocarbon group, n, p, and q are each independently an integer of 0 to 4, R^a and R^b are each independently a C1-12 alkyl, and X^a is a single bond, -O-, -S-, -S(O)-, -S(O)₂-, -C(O)-, or a C1-13 alkylidene of formula -C(R^c)(R^d)- wherein R^c and R^d are each independently hydrogen, C1-12 alkyl, or a group of the formula -C(=R^e)- wherein R^e is a divalent C1-12 hydrocarbon group. In some aspects, the bisphenol ester units may be bisphenol A phthalate ester units of the formula (5b)

[0025] In one or more aspects, the poly(bisphenol A carbonate-co-isophthalate/terephthalate- resorcinol ester) comprises 1 to 90 mol% of bisphenol A carbonate units, 10 to 99 mol% of isophthalic acid-terephthalic acid-resorcinol ester units, and optionally 1 to 60 mol% of resorcinol carbonate units, isophthalic acid-terephthalic acid-bisphenol A phthalate ester units, or a combination thereof. In another aspect, poly(bisphenol A carbonate-co-isophthalate/terephthalate resorcinol ester) comprises 10 to 20 mol% of bisphenol A carbonate units, 20-98 mol% of isophthalic acid-terephthalic acid-resorcinol ester units, and optionally 1 to 60 mol% of resorcinol carbonate units, isophthalic acid-terephthalic acid- bisphenol A phthalate ester units, or a combination thereof.

[0026] The poly(ester-carbonate)s may have a Mw of 2,000-100,000 g/mol, or 3,000-75,000 g/mol, or 4,000-50,000 g/mol, or 5,000-35,000 g/mol. Molecular weight determinations are performed using GPC using a cross linked styrene-divinyl benzene column, at a sample concentration of 1 mg/mL, and calibrated with polystyrene standards.

[0027] The polycarbonate composition may include a poly(aliphatic ester-carbonate) derived from a linear Ce-io aliphatic dicarboxylic acid (which includes a reactive derivative thereof), specifically a linear Ce-n aliphatic dicarboxylic acid(which includes a reactive derivative thereof). Specific dicarboxylic acids include n-hexanedioic acid (adipic acid), n-decanedioic acid (sebacic acid), and alpha, omega-Cu dicarboxylic acids such as dodecanedioic acid (DDDA). A specific poly(aliphatic ester) -polycarbonate is of formula (8) wherein each R¹ may be the same or different, and is as described in formula (1), m is 4 to 18, or 4 to 10, and the average molar ratio of ester units to carbonate units x:y is 99: 1 to 1:99, or 13:87 to 2:98, or 9:91 to 2:98, or 8:92 to 2:98. In one or more aspects, the poly(aliphatic ester)-polycarbonate copolymer comprises bisphenol A sebacate ester units and bisphenol A carbonate units, having, for example an average molar ratio of x:y of 2:98 to 8:92, for example 6:94.

[0028] The poly( aliphatic ester-carbonate) may have a Mw of 15,000 to 40,000 g/mol, or 20,000 to 38,000 g/mol as measured by GPC based on polystyrene standards.

[0029] The bromine-containing polycarbonate copolymer may be a brominated polycarbonate oligomer derived from brominated aromatic dihydroxy compounds (e.g., brominated compounds of formula (1)) and a carbonate precursor, or from a combination of brominated and non-brominated aromatic dihydroxy compounds, e.g., of formula (1), and a carbonate precursor. Brominated polycarbonate oligomers are disclosed, for example, in U.S. Pat. Nos. 4,923,933, 4,170,711, and 3,929,908. Examples of brominated aromatic dihydroxy compounds include 2,2-bis(3,5-dibromo-4- hydroxyphenyl)propane, bis(3,5-dibromo-4-hydroxyphenyl)menthanone, and 2,2',6,6'-tetramethyl- 3,3',5,5'-tetrabromo-4,4'-biphenol.

[0030] Examples of non-brominated aromatic dihydroxy compounds for copolymerization with the brominated aromatic dihydroxy compounds include bisphenol A, bis(4-hydroxyphenyl)methane, 2,2- bis(4-hydroxy-3-methylphenyl)propane, 4,4-bis(4-hydroxyphenyl)heptane, and (3,3'-dichloro-4,4'- dihydroxydiphenyl)methane. Combinations of two or more different brominated and non-brominated aromatic dihydroxy compounds can be used. If a combination of aromatic dihydroxy compounds is used, then the combinations can contain 25 to 55 mol% of the brominated aromatic dihydroxy compounds and 75 to 65 mol% of a non-brominated dihydric phenol. Various endcaps can be present, for example polycarbonates having phenol endcaps or 2,4,6-tribromophenol endcaps can be used.

[0031] In some aspects, a bromine-containing polycarbonate copolymer can include brominated carbonate units derived from 2,2',6,6'-tetrabromo-4,4'-isopropylidenediphenol (TBBPA) and carbonate units derived from at least one dihydroxy aromatic compound that is not TBBPA. The dihydroxy aromatic compound can be any one or more of those described herein. In a specific aspect, the dihydroxy aromatic compound is bisphenol A. The relative ratio of TBBPA to the dihydroxy aromatic compound used to manufacture the bromine-containing polycarbonate copolymer will depend in some aspects on the amount of the bromine-containing polycarbonate copolymer used and the amount of bromine desired in the polycarbonate composition. In one or more aspects, the bromine-containing polycarbonate copolymer is manufactured from a composition having 30 to 70 wt % of TBBPA and 30 to 70 wt % of the dihydroxy aromatic compound, specifically bisphenol A, or specifically 45 to 55 wt % of TBBPA and 45 to 55 wt % of the dihydroxy aromatic compound, specifically bisphenol A. In one or more aspects, no other repeating units are present in the bromine-containing polycarbonate copolymer. In some aspects, a combination of two or more different bromine-containing polycarbonate copolymers may be used. The bromine-containing polycarbonate copolymers can differ in one or more of a property (e.g., polydispersity or molecular weight) or a structural feature (e.g., the identity of the repeating units, the presence of copolymer units, or the amount of bromine in the polymer).

[0032] The bromine-containing polycarbonate may have a bromine content of 10 to 50 wt%, 15 to 40 wt%, 20 to 30 wt%, or 24 to 27.5 wt% each based on the weight of the bromine-containing polycarbonate. Optionally the bromine-containing polycarbonate can have phenol or 2,4,6- tribromophenol endcaps. The bromine-containing polycarbonate can have an intrinsic viscosity of 0.2 to 1.5 deciliter per gram, measured in methylene chloride at 25°C. Within this range, the intrinsic viscosity can be 0.4 to 1 deciliter per gram. The bromine-containing polycarbonate copolymer can have a Mw from 18,000 to 30,000 g/mol, or 20,000 to 30,000 g/mol, as measured by gel permeation chromatography (GPC) using polystyrene standards.

[0033] The bromine-containing polycarbonate is present in an amount effective to provide 1 to 15 wt% bromine content, based on the total weight of the polycarbonate composition. Within this range, the bromine-containing polycarbonate may be present in an amount effective to provide 1 to 10 wt%, 1 to 7 wt%, or 1 to 5 wt% bromine content, each based on the total weight of the polycarbonate composition.

[0034] In some aspects, the bromine-containing polycarbonate may have a bromine content of 20 to 30 wt%, or 24 to 27.5 wt%, each based on the weight of the bromine-containing polycarbonate and the bromine-containing polycarbonate may be present in an amount effective to provide 1 to 7 wt% or 1 to 6 wt% bromine content, each based on the total weight of the polycarbonate composition.

[0035] Polycarbonates may be manufactured by processes such as interfacial polymerization and melt polymerization, which are known, and are described, for example, in WO 2013/175448 Al and WO 2014/072923 Al.

[0036] Branched polycarbonate blocks may be prepared by adding a branching agent during polymerization, for example trimellitic acid, trimellitic anhydride, trimellitic trichloride, tris-p- hydroxyphenylethane, isatin-bis-phenol, tris-phenol TC (l,3,5-tris((p-hydroxyphenyl)isopropyl)benzene), tris-phenol PA (4(4(1, l-bis(p-hydroxyphenyl) -ethyl) alpha, alpha-dimethyl benzyl)phenol), 4- chloroformyl phthalic anhydride, trimesic acid, and benzophenone tetracarboxylic acid. The branching agents may be added at a level of 0.05 to 4.0 wt%, or 0.25 to 2.0 wt%, based on the total weight of the composition. Combinations comprising linear polycarbonates and branched polycarbonates may be used.

[0037] An end-capping agent (also referred to as a chain stopper agent or chain terminating agent) may be included during polymerization to provide end groups. The end-capping agent (and thus end groups) are selected based on the desired properties of the polycarbonates. Exemplary end-capping agents are exemplified by monocyclic phenols such as phenol and C1-22 alkyl-substituted phenols such as p-cumyl-phenol, resorcinol monobenzoate, and p-and tertiary-butyl phenol, monoethers of diphenols, such as p-methoxyphenol, and alkyl-substituted phenols with branched chain alkyl substituents having 8 to 9 carbon atoms, 4-substituted-2-hydroxybenzophenones and their derivatives, aryl salicylates, monoesters of diphenols such as resorcinol monobenzoate, 2-(2-hydroxyaryl)-benzotriazoles and their derivatives, 2-(2-hydroxyaryl)-l,3,5-triazines and their derivatives, mono-carboxylic acid chlorides such as benzoyl chloride, C1-22 alkyl-substituted benzoyl chloride, toluoyl chloride, bromobenzoyl chloride, cinnamoyl chloride, and 4-nadimidobenzoyl chloride, polycyclic, mono -carboxylic acid chlorides such as trimellitic anhydride chloride, and naphthoyl chloride, functionalized chlorides of aliphatic monocarboxylic acids, such as acryloyl chloride and methacryoyl chloride, and mono-chloroformates such as phenyl chloroformate, alkyl-substituted phenyl chloroformates, p-cumyl phenyl chloroformate, and toluene chloroformate. Combinations of different end groups may be used.

[0038] The polycarbonate compositions comprise a poly(carbonate-siloxane), also referred to as a “polycarbonate-polysiloxane copolymer” and is present in an amount effective to provide 1 to 10 wt% of total siloxane, based on the total weight of the polycarbonate composition. The polysiloxane blocks comprise repeating diorganosiloxane units, including those of formula (9): wherein each R is independently a C1-13 monovalent organic group. For example, R may be a C1-13 alkyl, Ci-is alkoxy, C2-13 alkenyl, C2-13 alkenyloxy, C3.6 cycloalkyl, C3.6 cycloalkoxy, Ce-i4 aryl, Ce-io aryloxy, C7-13 arylalkylene, C7-13 arylalkylenoxy, C7-13 alkylarylene, or C7-13 alkylaryleneoxy. The foregoing groups may be fully or partially halogenated with fluorine, chlorine, bromine, or iodine, or a combination thereof. Combinations of the foregoing R groups may be used in the same copolymer.

[0039] The value of E in formula (9) has an average value of 2 to 1,000, preferably 2 to 500, or 2 to 200, or 2 to 125, or 5 to 80, or 10 to 70. In one or more aspects, E has an average value of 10 to 80 or 10 to 40, and in still another aspect, E has an average value of 40 to 80, or 40 to 70. A combination of a first and a second (or more) poly(carbonate-siloxane) copolymers may be used, wherein the average value of E of the first copolymer is less than the average value of E of the second copolymer.

[0040] In one or more aspects, the polysiloxane blocks are of formula (10) wherein E and R are as defined in formula (9), each R may be the same or different, and is as defined in formula (9); and each Ar is the same or different, and is a substituted or unsubstituted Ce-so arylene. Ar groups in formula (10) may be derived from a Ce-so dihydroxyarylene compound. Exemplary dihydroxyarylene compounds include l,l-bis(4-hydroxyphenyl) methane, l,l-bis(4-hydroxyphenyl) ethane, 2,2-bis(4-hydroxyphenyl) propane, 2,2-bis(4-hydroxyphenyl) butane, 2,2-bis(4-hydroxyphenyl) octane, l,l-bis(4-hydroxyphenyl) propane, l,l-bis(4-hydroxyphenyl) n-butane, 2,2-bis(4-hydroxy-l- methylphenyl) propane, l,l-bis(4-hydroxyphenyl) cyclohexane, bis(4-hydroxyphenyl sulfide), l,l-bis(4- hydroxy-t-butylphenyl) propane, or the like, or a combination thereof.

[0041] In another aspect, polysiloxane blocks may be of formula (11) wherein R and E are as defined in formula (9), and each R⁵ is independently a divalent C1-30 organic group, and wherein the polymerized polysiloxane unit is the reaction residue of its corresponding dihydroxy compound. In a specific aspect, the polysiloxane blocks may be of formula (12): wherein R and E are as defined in formula (9). R⁶ in formula (12) is a divalent Cz-s aliphatic group. Each M in formula (12) is the same or different, and may be a halogen, cyano, nitro, Ci-s alkylthio, Ci-s alkyl, Ci-8 alkoxy, Cz-s alkenyl, Cz-s alkenyloxy, Cs-s cycloalkyl, Cs-s cycloalkoxy, Ce-io aryl, Ce-io aryloxy, C7-12 aralkyl, C7-12 aralkoxy, C7-12 alkylaryl, or C7-12 alkylaryloxy, wherein each n is independently 0 to 4.

[0042] In one or more aspects, M is bromo or chloro; an alkyl such as methyl, ethyl, or propyl; an alkoxy such as methoxy, ethoxy, or propoxy; or an aryl such as phenyl, chlorophenyl, or tolyl; R⁶ is a dimethylene, trimethylene, or tetramethylene; and R is Ci-s alkyl, Ci-s haloalkyl, C2-8 cyanoalkyl, or Ce-12 aryl. In another aspect, each R is methyl, or a combination of methyl and trifluoropropyl, or a combination of methyl and phenyl. In still another aspect, each R is methyl, each M is methoxy, n is 1, and R⁶ is a divalent C1-3 aliphatic group. Specific polysiloxane blocks include one or more of formulae

(13a), (13b), or (13c): wherein E has an average value of 2 to 200, 2 to 125, 5 to 125, 5 to 100, 5 to 50, 20 to 80, or 5 to 20.

[0043] Blocks of formulae (13a) to (13c) may be derived from the corresponding dihydroxy polysiloxane, which in turn may be prepared effecting a platinum-catalyzed addition between the siloxane hydride and an aliphatically unsaturated monohydric phenol such as eugenol, 2-alkylphenol, 4- allyl-2-methylphenol, 4-allyl-2-phenylphenol, 4-allyl-2-bromophenol, 4-allyl-2-t-butoxyphenol, 4- phenyl-2-phenylphenol, 2-methyl-4-propylphenol, 2-allyl-4,6-dimethylphenol, 2-allyl-4-bromo-6- methylphenol, 2-allyl-6-methoxy-4-methylphenol and 2-allyl-4,6-dimethylphenol. The polycarbonatesiloxane) copolymers may then be manufactured, for example, by the synthetic procedure of European

Pat. Pub. No. 0524731 Al.

[0044] The poly(carbonate-siloxane) copolymers may comprise 50 to 99 wt% of carbonate units and 1 to 50 wt% of siloxane units. Within this range, the poly(carbonate-siloxane) copolymer may comprise 70 to 98 wt%, or 75 to 97 wt% of carbonate units and 2 to 45 wt%, or 5 to 10 wt%, or 30 to 45 wt% of siloxane units.

[0045] In one or more aspects, a blend of a bisphenol A homopolycarbonate and a poly(carbonate-siloxane) block copolymer of bisphenol A blocks and eugenol capped polydimethylsiloxane blocks, of the formula below, may be used: wherein x is 1 to 200, or 5 to 85, or 10 to 70, or 15 to 65, or 40 to 60; x is 1 to 500, or 10 to 200, and z is 1 to 1000, or 10 to 800. In one or more aspects, x is 1 to 200, y is 1 to 90, and z is 1 to 600, and in another aspect, x is 30 to 50, y is 10 to 30, and z is 45 to 600. The polysiloxane blocks may be randomly distributed or controlled distributed among the polycarbonate blocks.

[0046] In one or more aspects, the poly(carbonate-siloxane) copolymer comprises 30 to 70 wt%, or 35 to 65 wt%, or 35 to 55 wt%, or 35 to 45 wt% of the polysiloxane based on the total weight of the poly(carbonate-siloxane) copolymer.

[0047] The poly(carbonate-siloxane) copolymer may include a single poly(carbonate siloxane). In certain aspects, the polycarbonate compositions include a poly(carbonate-siloxane) copolymer comprising 10 wt% or less of siloxane content, a poly(carbonate-siloxane) copolymer comprising 30 to 70 wt% of siloxane content, or. a poly(carbonate-siloxane) copolymer comprising greater than 10 to less than 30 wt% siloxane content. The poly(carbonate-siloxane) copolymer may include a combination of poly(carbonate-siloxane) copolymers, for example a combination of two or more of the foregoing. The polycarbonate compositions may include a poly(carbonate-siloxane) copolymer comprising 10 wt% or less siloxane content, a poly(carbonate-siloxane) copolymer comprising greater than 10 to less than 30 wt% of siloxane content, a poly(carbonate-siloxane) copolymer comprising 30 to 70 wt% of siloxane content, or a combination thereof, each based on the total weight of each poly(carbonate-siloxane) copolymer. In certain aspects, the polycarbonate compositions include a poly(carbonate-siloxane) copolymer comprising 10 wt% or less of siloxane content and a poly(carbonate-siloxane) copolymer comprising 30 to 70 wt% of siloxane content, each based on the total weight of each poly(carbonate- siloxane) copolymer.

[0048] The poly(carbonate-siloxane) may have a Mw of 2,000 to 100,000 g/mol, or 5,000 to 50,000 g/mol, as measured by GPC using a crosslinked styrene-divinyl benzene column, at a sample concentration of 1 mg/mL, using polystyrene standards.

[0049] The poly(carbonate-siloxane) may have an MFR, measured at 300°C/1.2 kg, of 1 to 50 cm³/10 min. Combinations of the poly(carbonate-siloxane)s of different flow properties may be used to achieve the overall desired flow property.

[0050] The one or more poly(carbonate-siloxane)s are present in an amount effective to provide 1 to 10 wt% total siloxane content, based on the total weight of the polycarbonate composition. Within this range, the one or more poly(carbonate-siloxane)s may be present in amount effective to provide 2 tolO wt%, 3 to 10 wt%, 3.5 to 10 wt%, 4 to 10 wt%, 2 to 8 wt%, 3 to 8 wt%, 3.5 to 8 wt%, or 4 to 8 wt% total siloxane content based on the total weight of the polycarbonate composition.

[0051] The polycarbonate compositions may be substantially free of polyetherimide, substantially free of an elastomer-modified graft copolymer, or a combination thereof. In some aspects, the polycarbonate compositions are “substantially free of polyetherimide.” As used herein, “substantially free of polyetherimide” means 5 wt% or less, 1 wt% or less, 0.5 wt% or less, 0.1 wt% or less, 0.05 wt% or less, 0.01 wt% or less, or less than 0.01 wt% of polyetherimide is present, based on the total weight of the polycarbonate composition. In some aspects, the polycarbonate compositions are “substantially free of an elastomer-modified graft copolymer.” As used herein, “substantially free of an elastomer-modified graft copolymer” means 5 wt% or less, 1 wt% or less, 0.5 wt% or less, 0.1 wt% or less, 0.05 wt% or less, 0.01 wt% or less, or less than 0.01 wt% of an elastomer-modified graft copolymer is present based on the total weight of the polycarbonate composition.

[0052] The polycarbonate composition further includes a glass-containing reinforcing agent. The term “glass” refers to a material, natural or synthetic, which contains silicon dioxide (SiOz) or silica as its main material. Preferably, the glass-containing reinforcing agent is glass fiber, milled glass, glass bead, glass flake, or a combination thereof.

[0053] The glass fibers may be textile glass fibers such as E, A, C, ECR, R, S, D, and/or NE glass fibers, and are desirably E type glass fibers. The glass fibers may be provided in the form of monofilament or multifilament fibers and may be used either alone or in combination with other types of fibers, for example, co-weaving or core/sheath, side-by-side, skin-core type or matrix and fibril constructions. The glass fibers may be supplied in the form of rovings, woven fibrous reinforcements, such as 0-90 degree fabrics or the like; non-woven fibrous reinforcements such as continuous strand mat, chopped strand mat, tissues, papers and felts or the like; or three-dimensional reinforcements such as braids. The preferred filaments for plastic reinforcement are made by mechanical pulling.

[0054] The glass fiber may be a chopped glass fiber, long glass fiber, glass filament, woven glass fiber, or a combination thereof. In one or more aspects, the glass fiber may further be combined with carbon fiber, woven carbon fiber, ceramic fiber, or a combination thereof. The glass fibers may be continuous or chopped, preferably chopped. Glass fibers in the form of chopped strands may have a length of 0.3 millimeters (mm) to 10 centimeters (cm), preferably 0.5 mm to 5 cm or 3 mm to 13 mm. The glass fibers may have a length from 0.2-20 mm, preferably 0.2-10 mm, more preferably 0.7-7 mm. The glass fibers may have any cross-section, such as a round (or circular), flat, bilobe, or irregular crosssection. The average diameter of the glass fibers may be from 1-25 micrometers (pm), preferably 3-20 pm, more preferably 4-18 pm, even more preferably 5-17 pm. The glass fiber may be a short glass fiber having a diameter of 10 pm or 14 pm. In one or more aspects, the glass fiber has a circular cross-section. Flat glass or bilobe fibers may be used to provide, for example, low warp-high strength-high elongation articles. The glass fiber may have a round (or circular), flat, or irregular cross-section. Thus, use of nonround fiber cross sections is possible. However, in some examples, the glass fiber may have a circular cross-section. The width or diameter of the glass fiber may be from about 1 to about 20 pm, or from about 5 to about 20 pm. In a further example, the width or diameter of the glass fiber may be from about 5 to about 15 pm. In certain compositions, the glass fiber may have a width or diameter of about 14 pm.

[0055] The glass fibers may be bonding or non-bonding. As used herein, “non-bonding glass fiber” means the glass fiber is coated with a sizing composition that results in poor adhesion of the coated glass fiber to the polycarbonate matrix. In other words, a non-bonding glass fiber is coated with a sizing composition that is incompatible with the polycarbonate matrix, which is in contrast to a non-bonding glass fiber coated with a sizing composition that has improved adhesion with the polycarbonate matrix (herein referred to as “bonding glass fibers” because they are bonding with respect to the polycarbonate).

[0056] The glass-containing reinforcing agent of the polycarbonate composition is present from 5 to 30 wt%, 5 to 25 wt%, 5 to 20 wt%, or 10-20 wt%, based on the total weight of the composition. The glass-containing reinforcing agents may include a combination including glass fiber and milled glass. The glass fiber may be present in an amount from 1 to 25 wt%, 4 to 20 wt%, ; and the milled glass may be present from 0.1 to 15 wt%, or 1 to 10 wt%, each based on the total weight of the polycarbonate composition.

[0057] The polycarbonate composition optionally may include a mineral filler, for example up to 10 wt% of a mineral filler comprising talc, kaolin, calcium carbonate, wollastonite, or a combination thereof, for example, calcium carbonates such as chalk, limestone, marble, synthetic precipitated calcium carbonates, or the like; talc, such as fibrous, modular, needle shaped, lamellar talc, or the like; wollastonite; surface-treated wollastonite; and kaolin, such as hard kaolin, soft kaolin, calcined kaolin, kaolin comprising various coatings known in the art to facilitate compatibility with the polymer matrix.

[0058] Additional mineral fillers or reinforcing agents may also be present. Possible additional fillers or reinforcing agents include, for example, silicates and silica powders such as aluminum silicate (mullite), synthetic calcium silicate, zirconium silicate, fused silica, crystalline silica graphite, natural silica sand, or the like; boron powders such as boron-nitride powder, boron-silicate powders, or the like; oxides such as TiOz, aluminum oxide, magnesium oxide, or the like; calcium sulfate (as its anhydride, dihydrate or trihydrate); glass spheres such as hollow and solid glass spheres, silicate spheres, cenospheres, aluminosilicate (armospheres), or the like; or the like; single crystal fibers or “whiskers” such as silicon carbide, alumina, boron carbide, iron, nickel, copper, or the like; fibers (including continuous and chopped fibers) such as asbestos, carbon fibers, sulfides such as molybdenum sulfide, zinc sulfide or the like; barium compounds such as barium titanate, barium ferrite, barium sulfate, heavy spar, or the like; metals and metal oxides such as particulate or fibrous aluminum, bronze, zinc, copper and nickel or the like; flaked fillers such as glass flakes, flaked silicon carbide, aluminum diboride, aluminum flakes, steel flakes or the like; fibrous fillers, for example short inorganic fibers such as those derived from blends comprising at least one of aluminum silicates, aluminum oxides, magnesium oxides, and calcium sulfate hemihydrate or the like; natural fillers and reinforcements, such as wood flour obtained by pulverizing wood, fibrous products such as cellulose, cotton, sisal, jute, starch, cork flour, lignin, ground nut shells, corn, rice grain husks or the like; organic fillers such as polytetrafluoroethylene; reinforcing organic fibrous fillers formed from organic polymers capable of forming fibers such as poly(ether ketone), polyimide, polybenzoxazole, poly(phenylene sulfide), polyesters, polyethylene, aromatic polyamides, aromatic polyimides, polyetherimides, polytetrafluoroethylene, acrylic polymers, poly(vinyl alcohol) or the like; as well as additional fillers and reinforcing agents such as mica, clay, feldspar, flue dust, fillite, quartz, quartzite, perlite, tripoli, diatomaceous earth, carbon black, or the like, or a combination thereof.

[0059] The fillers and reinforcing agents may be coated with a layer of metallic material to facilitate conductivity, or surface treated with silanes to improve adhesion and dispersion with the polymer matrix. In addition, the reinforcing fillers may be provided in the form of monofilament or multifilament fibers and may be used individually or in combination with other types of fiber, through, for example, co-weaving or core/sheath, side-by-side, orange-type or matrix and fibril constructions, or by other methods known to one skilled in the art of fiber manufacture. Co-woven structures include glass fiber-carbon fiber, carbon fiber-aromatic polyimide (aramid) fiber, and aromatic polyimide fiberglass fiber or the like. Fibrous fillers may be supplied in the form of, for example, rovings, woven fibrous reinforcements, such as 0-90 degree fabrics or the like; non-woven fibrous reinforcements such as continuous strand mat, chopped strand mat, tissues, papers and felts or the like; or three-dimensional reinforcements such as braids.

[0060] The polycarbonate compositions optionally may include an organophosphorous flame retardant, for example an organophosphorous flame retardant in amount effective to provide up to 1.5 wt% of phosphorous, based on the total weight of the polycarbonate composition. Exemplary aromatic organophosphorous compounds have at least one organic aromatic group that may be a substituted or unsubstituted C3-30 group containing one or more of a monocyclic or polycyclic aromatic moiety (which may optionally contain with up to three heteroatoms (N, O, P, S, or Si)) and optionally further containing one or more nonaromatic moieties, for example alkyl, alkenyl, alkynyl, or cycloalkyl. The aromatic moiety of the aromatic group may be directly bonded to the phosphorous-containing group, or bonded via another moiety, for example an alkylene group. In one or more aspects, the aromatic group of the organophosphorous flame retardant is the same as the aromatic group of the homopolycarbonate.

[0061] The phosphorous-containing group may be a phosphate (P(=O)(OR)s), phosphite (P(OR)s), phosphonate (RP(=O)(OR)z), phosphinate (R2P(=O)(OR)), phosphine oxide ( R₃P(=O)), or phosphine (R3P), wherein each R in the foregoing phosphorous-containing groups may be the same or different, provided that at least one R is an aromatic group. A combination of different phosphorous- containing groups may be used. The aromatic group may be directly or indirectly bonded to the phosphorous, or to an oxygen of the phosphorous-containing group (i.e., an ester).

[0062] In one or more aspects, the aromatic organophosphorous compound may be a monomeric phosphate. Representative monomeric aromatic phosphates are of the formula (GO)sP=O, wherein each G is independently an alkyl, cycloalkyl, aryl, alkylarylene, or arylalkylene group having up to 30 carbon atoms, provided that at least one G is an aromatic group. Two G groups may be joined together to provide a cyclic group. In some aspects ,G corresponds to a monomer used to form the polycarbonate, e.g., resorcinol. Exemplary phosphates include phenyl bis(dodecyl) phosphate, phenyl bis(neopentyl) phosphate, phenyl bis(3,5,5'-trimethylhexyl) phosphate, ethyl diphenyl phosphate, 2-ethylhexyl di(p- tolyl) phosphate, bis(2-ethylhexyl) p-tolyl phosphate, tritolyl phosphate, bis ( -ethylhexyl) phenyl phosphate, tri(nonylphenyl) phosphate, bis(dodecyl) p-tolyl phosphate, dibutyl phenyl phosphate, 2- chloroethyl diphenyl phosphate, p-tolyl bis(2,5 ,5 '-trimethylhexyl) phosphate, 2-ethylhexyl diphenyl phosphate, and the like. A specific aromatic phosphate is one in which each G is aromatic, for example, triphenyl phosphate, tricresyl phosphate, isopropylated triphenyl phosphate, and the like.

[0063] Di- or polyfunctional aromatic organophosphorous compounds may be used and include, for example, compounds of the formulae wherein each G¹ is independently a C1-30 hydrocarbyl; each G² is independently a C1-30 hydrocarbyl or hydrocarbyloxy; X^a is as defined in formula (3) or formula (4); each X is independently a bromine or chlorine; m is an integer of 0 to 4, and n is an integer of 1 to 30. In a specific aspect, X^a is a single bond, methylene, isopropylidene, or 3,3,5-trimethylcyclohexylidene.

[0064] Specific aromatic organophosphorous compounds are inclusive of acid esters of formula

(14): wherein each R¹⁶ is independently Ci-s alkyl, C5.6 cycloalkyl, Ce-zo aryl, or C7-12 arylalkylene, each optionally substituted by C1-12 alkyl, specifically by C1-4 alkyl and X is a mono- or poly-nuclear aromatic Ce-so moiety or a linear or branched C2-30 aliphatic radical, which may be OH- substituted and may contain up to 8 ether bonds, provided that at least one R¹⁶ or X is an aromatic group; each n is independently 0 or 1; and q is from 0.5 to 30. In some aspects each R¹⁶ is independently C1-4 alkyl, naphthyl, phenyl(Ci. 4)alkylene, aryl groups optionally substituted by C 1 -4 alkyl; each X is a mono- or poly-nuclear aromatic Ce-so moiety, each n is 1; and q is 0.5 to 30. In some aspects, each R¹⁶ is independently aromatic, e.g., phenyl; each X is a mono- or poly-nuclear aromatic Ce-so moiety, including a moiety derived from formula (2); n is 1; and q is 0.8 to 15. In other aspects, each R¹⁶ is phenyl; X is cresyl, xylenyl, propylphenyl, butylphenyl, one of the following divalent groups or a combination thereof; n is 1; and q is 1 to 5, or 1 to 2. In some aspects, at least one R¹⁶ or X corresponds to a monomer used to form the polycarbonate, e.g., bisphenol A, resorcinol, or the like. Aromatic organophosphorous compounds of this type include the bis(diphenyl) phosphate of hydroquinone, resorcinol bis(diphenyl phosphate) (RDP), and bisphenol A bis(diphenyl) phosphate (BPADP), and their oligomeric and polymeric counterparts.

[0065] The organophosphorous flame retardant may include a phosphorous-nitrogen bond, and may be a phosphazene, phosphonitrilic chloride, phosphorous ester amide, phosphoric acid amide, phosphonic acid amide, phosphinic acid amide, or tris(aziridinyl) phosphine oxide. In one or more aspects, the organophosphorous flame retardant contains a phosphorous-nitrogen bond and is a phosphazene or cyclic phosphazene of the formulae: wherein wl is 3 to 10,000; w2 is 3 to 25, or 3 to 7; and each R^w is independently C1-12 alkyl, C2-12 alkenyl, C1-12 alkoxy, Ce-i2 aryl, Ce-i2 aryloxy, or poly(Ci-6 alkylene oxide). In the foregoing groups, at least one hydrogen atom may be substituted with a group having an N, S, O, or F atom, or an amino group. For example, each R^w may be a substituted or unsubstituted phenoxy, an amino, or a poly(Ci-6 alkylene oxide). Optionally, R^w may form a crosslink to another phosphazene group. Exemplary crosslinks include bisphenol groups, for example bisphenol A groups. In one or more aspects, the organophosphorous flame retardant is a phosphazene that has a structure represented by the formula:

[0066] The organophosphorous flame retardant may be present in an amount effective to provide up to 1.5 wt%, or up to 1.2 wt%, or up to 1.0 wt%, or up to 0.8 wt%, or up to 0.6 wt%, or up to 0.4 wt% of phosphorous, based on the total weight of the polycarbonate composition.

[0067] The polycarbonate composition optionally may further include one or more flame retardants in addition to the organophosphorous flame retardant. Inorganic flame retardants may be used, for example salts of C2-16 alkyl sulfonates such as potassium perfluorobutane sulfonate (Rimar salt), potassium perfluoroctane sulfonate, and tetraethylammonium perfluorohexane sulfonate, salts of aromatic sulfonates such as sodium benzene sulfonate, sodium toluene sulfonate (NATS), or the like, salts of aromatic sulfone sulfonates such as potassium diphenylsulfone sulfonate (KSS), or the like; salts formed by reacting for example an alkali metal or alkaline earth metal (e.g., lithium, sodium, potassium, magnesium, calcium and barium salts) and an inorganic acid complex salt, for example, an oxo- anion (e.g., alkali metal and alkaline-earth metal salts of carbonic acid, such as NazCOs, K2CO3, MgCOs, CaCOs, or BaCOs, or a fluoro-anion complex such as Li ;AIF₍„ BaSiFe, KBF4, K3AIF6, KAIF4, KzSiFe, or asAIFf, or the like. When used, the perfluoroalkyl sulfonate salt may be present in an amount of 0.30 to 1.00 wt%, or 0.40 to 0.80 wt%, or 0.45 to 0.70 wt%, based on the total weight of the composition. When used, the aromatic sulfonate salt may be present in an amount of 0.01 to 0.1 wt%, or 0.02 to 0.06 wt%, or 0.03 to 0.05 wt%.

[0068] Halogenated materials optionally may be used as flame retardants in addition to the organophosphorous flame retardant, for example bisphenols of which the following are representative: 2,2-bis-(3,5-dichlorophenyl)-propane; bis-(2-chlorophenyl)-methane; bis(2,6-dibromophenyl)-methane; l,l-bis-(4-iodophenyl)-ethane; l,2-bis-(2,6-dichlorophenyl)-ethane; l,l-bis-(2-chloro-4- iodophenyl)ethane; l,l-bis-(2-chloro-4-methylphenyl)-ethane; l,l-bis-(3,5-dichlorophenyl)-ethane; 2,2- bis-(3-phenyl-4-bromophenyl)-ethane; 2,6-bis-(4,6-dichloronaphthyl)-propane; and 2,2-bis-(3,5-dichloro- 4-hydroxyphenyl)-propane 2,2 bis-(3-bromo-4-hydroxyphenyl)-propane. Other halogenated materials include 1,3-dichlorobenzene, 1,4-dibromobenzene, l,3-dichloro-4-hydroxybenzene, and biphenyls such as 2,2'-dichlorobiphenyl, polybrominated 1,4-diphenoxybenzene, 2,4'-dibromobiphenyl, 2,4'- dichlorobiphenyl, and decabromo diphenyl oxide. Metal synergists, e.g., antimony oxide, may also be used with the flame retardant. When present, these halogen-containing flame retardants are present in amounts of 1 to 25 parts by weight, more preferably 2 to 20 parts by weight, based on 100 parts by weight of the total composition, excluding any filler. It is noted that these halogen-containing flame retardants do not include a bromine-containing polycarbonate copolymer.

[0069] Anti-drip agents may also be used in the composition, for example a fibril-forming fluoropolymer or a non-fibril forming fluoropolymer such as polytetrafluoroethylene (PTFE). The antidrip agent may be encapsulated by a rigid copolymer, for example styrene-acrylonitrile copolymer (SAN). PTFE encapsulated in SAN is known as TSAN. An TSAN comprises 50 wt% of PTFE and 50 wt% of SAN, based on the total weight of the encapsulated fluoropolymer. The SAN may comprise, for example, 75 wt% of styrene and 25 wt% of acrylonitrile, based on the total weight of the copolymer. Anti-drip agents may be used in amounts of 0.1 to 10 parts by weight, based on 100 parts by weight of the total composition.

[0070] In one or more aspects, the polycarbonate composition may include 35 to 70 wt% of a homopolycarbonate; 10 to 25 wt% of a bromine-containing polycarbonate copolymer; 10 to 60 wt% of a poly(carbonate-siloxane), present in an amount effective to provide 1 to 10 wt% of total siloxane, based on the total weight of the polycarbonate composition; 4 to 20 wt% of glass fiber; 1 to 10 wt% of milled glass; and optionally, 1 to 5 wt% of an organophosphorous flame retardant in amount effective to provide up to 1.5 wt% of phosphorous, based on the total weight of the polycarbonate composition; wherein each amount is based on the total weight of the polycarbonate composition.

[0071] In one or more aspects, the polycarbonate composition may include 35 to 70 wt% of a poly(phthalate-carbonate); 10 to 25 wt% of a bromine-containing polycarbonate copolymer; 10 to 60 wt% of a poly(carbonate-siloxane), present in an amount effective to provide 1 to 10 wt% of total siloxane, based on the total weight of the polycarbonate composition; 4 to 20 wt% of glass fiber; 1 to 10 wt% of milled glass; and optionally, 1 to 5 wt% of an organophosphorous flame retardant in amount effective to provide up to 1.5 wt% of phosphorous, based on the total weight of the polycarbonate composition; wherein each amount is based on the total weight of the polycarbonate composition.

[0072] In one or more aspects, the polycarbonate composition may include 35 to 70 wt% of a combination of poly(phthalate-carbonate) and optionally, a homopolycarbonate; 10 to 25 wt% of a bromine-containing polycarbonate copolymer; 10 to 60 wt% of a poly(carbonate-siloxane), present in an amount effective to provide 1 to 10 wt% of total siloxane, based on the total weight of the polycarbonate composition; 4 to 20 wt% of glass fiber; 1 to 10 wt% of milled glass; and optionally, 1 to 5 wt% of an organophosphorous flame retardant in amount effective to provide up to 1.5 wt% of phosphorous, based on the total weight of the polycarbonate composition; wherein each amount is based on the total weight of the polycarbonate composition.

[0073] The polycarbonate compositions may be manufactured by various methods. For example, powdered polycarbonate, and optional components are first blended, optionally with fillers in a HENSCHEL high speed mixer. Other low shear processes, including but not limited to hand mixing, may also accomplish this blending. The blend is then fed into the throat of a twin-screw extruder via a hopper. Alternatively, at least one of the components may be incorporated into the composition by feeding directly into the extruder at the throat or downstream through a side-stuff er. Additives may also be compounded into a masterbatch with a desired polymeric polymer and fed into the extruder. The extruder is generally operated at a temperature higher than that necessary to cause the composition to flow. The extrudate is immediately quenched in a water bath and pelletized. The pellets so prepared may be one- fourth inch long or less as desired. Such pellets may be used for subsequent molding, shaping, or forming.

[0074] Shaped, formed, or molded articles comprising the polycarbonate compositions are also provided. The polycarbonate compositions may be molded into useful shaped articles by a variety of methods, such as molding, casting, or extruding the polycarbonate composition. Molding can include injection molding, extrusion, rotational molding, blow molding, and thermoforming. In one or more aspects, the article is an extruded article, a molded article, pultruded article, a thermoformed article, a foamed article, a layer of a multi-layer article, a substrate for a coated article, or a substrate for a metallized article.

[0075] Transportation components, in particular interior train components that are molded or extruded from the polycarbonate compositions are also provided. Molding may be by a variety of means such as injection molding, rotational molding, blow molding, or the like. In one or more aspects, the molding is by injection molding. Illustrative claddings include, for example interior vertical surfaces, such as side walls, front walls, end-walls, partitions, room dividers, flaps, boxes, hoods and louvres; interior doors and linings for internal and external doors; window insulations, kitchen interior surfaces, interior horizontal surfaces, such as ceiling paneling, flaps, boxes, hoods and louvres; luggage storage areas, such as overhead and vertical luggage racks, luggage containers and compartments; driver’s desk applications, such as paneling and surfaces of driver’s desk; interior surfaces of gangways, such as interior sides of gangway membranes (bellows) and interior linings; window frames (including sealants and gaskets); (folding) tables with downward facing surface; interior and exterior surface of air ducts, and devices for passenger information (such as information display screens) and the like.

[0076] In some aspects, the article may be an interior railway component, including, for example, a seat component, an extruded interior cladding, a molded interior cladding, a side wall, a front wall, an end wall, a partition, a room divider, a flap, a box, a hood, a louvre, a ceiling panel, a table tray, a head rest, a privacy divider, a center console, an arm rest, a leg rest, a food tray, an end bay, a shroud, a kick panel, a foot well, literature pocket, a monitor, a bezel, a line replaceable unit, a foot bar, a luggage rack, a luggage container, a luggage compartment, a floor composite, a wall composite, an air duct, a strip, a device for passenger information, a window frame, an interior lining, an interior vertical surface, an interior door, a lining for an internal door, a lining for an external door, an interior horizontal surface, an electrical component, or a lighting component.

[0077] The smoke density and maximum heat release rate values for hazard levels HL1 to HL3 in the European Railway standard EN-45545 (2013) are shown in Table 1 for R1 and R6 applications combined.

Table 1

[0078] Data in the Examples below shows that the compositions herein may meet the requirements for HL2, for both R1 and R6 applications.

[0079] While the compositions described herein are designed for use preferably in railway interiors, it is to be understood that the compositions are also useful in other interior components that are required to meet the test standards for HL2 for both R1 and R6 applications. Interior bus components are preferably mentioned. Current discussions directed to increasing bus safety include proposals to apply the HL2 standards to interior bus components. One or more aspects accordingly provide interior bus components, including seat components and claddings as described above and comprising the polycarbonate compositions described herein.

[0080] This disclosure is further illustrated by the following examples, which are non-limiting.

EXAMPLES

[0081] The following components shown in Table 2 were used in the examples.

Table 2

[0082] The testing samples were prepared as described below and the following test methods were used.

[0083] Typical compounding procedures are described as follows: All raw materials were compounded on a 25 millimeter (mm) co-rotating twin-screw extruder with a vacuum vented standard mixing screw (Werner Pfleiderer ZSK) operated at a screw speed of 300 revolutions per minute (rpm). The glass fiber (GF) was added using a side-feeder that was positioned down-stream. The strands were cooled through a water bath prior to being formed into pellets (pelletizing). The pellets were subsequently dried for 3 to 4 hours at 90°C to 110°C in a forced air-circulating oven prior to injection molding. A molding machine (Engel 45, 75, or 90 tons) was used to mold test parts for testing.

[0084] The compounding conditions are provided in Table 3.

Table 3

[0085] The molding conditions are provided in Table 4.

Table 4

[0086] The sheet extrusion conditions are provided in Table 5.

Table 5

[0087] Sample testing methods are shown in Table 6.

Table 6

[0088] Samples were prepared and tested. Table 7 shows the compositions and properties for Example 1 (El) and Comparative Example 1 (CE1), where the amounts are expressed in weight percent (wt%) based on 100 wt% total for the composition. The CTQ refers to a desirable cutoff point for properties.

Table 7

[0089] As shown in Table 7, the composition of Example 1, which includes homopolycarbonate, poly(carbonate-siloxane), and bromo-substituted polycarbonate copolymer, achieves the desired combination of properties: a Charpy notched impact of greater than 6 kJ/m², a tensile modulus of greater than 4,000 MPa, a Vicat B120 of greater than 100°C, a density of less than 1.38, a smoke density DS-4 of less than or equal to 300, a smoke density VOF4 of less than or equal to 600, a MAHRE value of less than or equal to 90, and a critical flux at extinguishment (CFE) of greater than or equal to 20 kW/m² at thickness of 2 to 3 mm.

[0090] Comparative Example 1, which did not include the bromo-substituted polycarbonate copolymer, only satisfied the requirements for EN45545-R1 at CFE of 2 mm (must be above 20 kW/m² to meet this regulatory standard), and could not be achieved at 3 mm. This shows that the use of the bromo-substituted polycarbonate copolymer in the inventive compositions provides unexpected improvements to CFE, such as satisfying the EN45545-R1 requirements at a thickness of 3 mm. This larger thickness is more typical for components and part used in rail wall panels.

[0091] Examples 2 through 7 (E2 to E7) include a combination of glass fibers and milled glass. Example 2 includes a poly(phthalate-carbonate) instead of homopolycarbonate. Examples 2 through 7 achieved a Charpy notched impact of greater than 6 kJ/m², a tensile modulus of greater than 4,000 MPa, a smoke density DS-4 of less than or equal to 300, a MAHRE value of less than or equal to 90, and a critical flux at extinguishment (CFE) of greater than or equal to 20 kW/m² at thickness of 3 mm.

[0092] This disclosure further encompasses the following aspects.

[0093] Aspect 1. A polycarbonate composition, comprising 10 to 80 wt%, or 20 to 75 wt%, or 35 to 70 wt% of a homopolycarbonate, a poly(phthalate-carbonate), or a combination thereof; 10 to 30 wt%, or 10 to 25 wt% of a bromine-containing polycarbonate copolymer; 5 to 60 wt%, or 10 to 60 wt% of a poly(carbonate-siloxane), present in an amount effective to provide 1 to 10 wt% of total siloxane, based on the total weight of the polycarbonate composition; 5 to 30 wt% of a glass-containing reinforcing agent; optionally, up to 10 wt% of a mineral filler, preferably wherein the mineral filler comprises talc, kaolin, calcium silicate, calcinated kaolin, calcium carbonate, wollastonite, or a combination thereof; optionally, an organophosphorous flame retardant in amount effective to provide up to 1.5 wt% of phosphorous, based on the total weight of the polycarbonate composition; and optionally, up to 10 wt% of an additive, wherein the amount of homopolycarbonate, poly(phthalate-carbonate, bromine-containing polycarbonate copolymer, poly(carbonate-siloxane), glass-containing reinforcing agent, optional mineral filler, optional organophosphorous flame retardant, and optional additive total 100 wt%..

[0094] Aspect la. The polycarbonate composition of aspect 1 comprising 5 to 20 wt% or 5 to 15 wt% of the glass-containing reinforcing agent.

[0095] Aspect lb. The polycarbonate composition of any one of the preceding aspects, wherein the poly(carbonate-siloxane) is present in an amount effective to provide 2 tolO wt%, 3 to 10 wt%, 3.5 to 10 wt%, 4 to 10 wt%, 2 to 8 wt%, 3 to 8 wt%, 3.5 to 8 wt%, or 4 to 8 wt% total siloxane content based on the total weight of the polycarbonate composition.

[0096] Aspect 1c. The polycarbonate composition of any one of the preceding aspects, wherein the bromine-containing polycarbonate copolymer is present in amount effective to provide 1 to 15 wt%, 1 to 10 wt%, 1 to 7 wt%, or 1 to 5 wt% total bromine content, each based on the total weight of the polycarbonate composition.

[0097] Aspect Id. The polycarbonate composition of any one of the preceding aspects, wherein the bromine-containing polycarbonate copolymer has a bromine content of 10 to 50 wt%, 15 to 40 wt%, 20 to 30 wt%, or 24 to 27.5 wt% each based on the weight of the bromine-containing polycarbonate copolymer.

[0098] Aspect le. The polycarbonate composition of any one of the preceding aspects, wherein the organophosphorous flame retardant is present in an amount effective to provide up to 1 wt%, up to 0.6 wt%, or up to 0.4 wt% phosphorous, based on the total weight of the polycarbonate composition.

[0099] Aspect 2. The polycarbonate composition of any one of the preceding aspects, wherein the polycarbonate composition does not further comprise a polyetherimide. [0100] Aspect 3. The polycarbonate composition of any one of the preceding aspects, wherein a molded sample of the composition has: a smoke density after 4 minutes (DS-4) of 300 or less, measured in accordance with ISO 5659-2 on a 3 mm thick plaque at 50 kW/m²; an integral of smoke density as a function of time after 4 minutes (VOF4) of 600 or less, measured in accordance with ISO 5659-2 on a 3 mm thick plaque at 50 kW/m²; a maximum average heat release (MAHRE) of 90 kW/m² or less, measured in accordance with ISO 5660-1 on a 3 mm thick plaque at 50 kW/m²; a critical heat flux at extinguishment (CFE) of 20 kW/m²or greater, measured in accordance with ISO 5658-2 on a 3 mm thick plaque; or a combination thereof.

[0101] Aspect 4. The polycarbonate composition of any one of the preceding aspects, wherein the poly(carbonate-siloxane) comprises a poly(carbonate-siloxane) copolymer comprising 10 wt% or less of siloxane content, a poly(carbonate-siloxane) copolymer comprising greater than 10 to less than 30 wt% of siloxane content, a poly(carbonate-siloxane) copolymer comprising 30 to 70 wt% of siloxane content, or a combination thereof, wherein each amount is based on total weight of each poly(carbonate-siloxane) copolymer.

[0102] Aspect 4a. The polycarbonate composition of any one of the preceding aspects, wherein the poly(carbonate-siloxane) comprises a poly(carbonate-siloxane) copolymer comprising greater than 10 to less than 30 wt% of siloxane content, based on total weight of each poly(carbonate-siloxane) copolymer.

[0103] Aspect 4b. The polycarbonate composition of any one of the preceding aspects, wherein the poly(carbonate-siloxane) comprises a poly(carbonate-siloxane) copolymer comprising 30 to 70 wt% of siloxane content, or a combination thereof, wherein each amount is based on total weight of each poly(carbonate-siloxane) copolymer.

[0104] Aspect 5. The polycarbonate composition of any one of the preceding aspects, wherein the glass-containing reinforcing agent is glass fiber, milled glass, glass bead, glass flake, or a combination thereof, preferably wherein the glass-containing reinforcing agent is glass fiber, milled glass, or a combination thereof.

[0105] Aspect 6a. The polycarbonate composition of any one of the preceding aspects, wherein the glass-containing reinforcing agent comprises: 4 to 20 wt% of glass fiber; and 1 to 10 wt% of milled glass, wherein each amount is based on the total weight of the polycarbonate composition.

[0106] Aspect 6b. The polycarbonate composition of any one of the preceding aspects, wherein the glass-containing reinforcing agent comprises: 4 to 20 wt% of glass fiber, preferably 4 to 15 wt%; and 1 to 10 wt% of milled glass, wherein each amount is based on the total weight of the polycarbonate composition.

[0107] Aspect 6c. The polycarbonate composition of any one of the preceding aspects, wherein the glass-containing reinforcing agent comprises: 4 to 20 wt% of glass fiber, preferably 4 to 15 wt%; and 1 to 10 wt%, preferably 1 to 5 wt% of the mineral filler, preferably talc.

[0108] Aspect 7. The polycarbonate composition of any one of the preceding aspects, wherein the organophosphorous flame retardant comprises a C3-30 aromatic group and a phosphate group, phosphite group, phosphonate group, phosphinate group, phosphine oxide group, phosphine group, phosphazene, or a combination comprising at least one of the foregoing phosphorus-containing groups.

[0109] Aspect 8. The polycarbonate composition of any one of the preceding aspects, wherein the organophosphorous flame retardant comprises a monomeric or oligomeric phosphate (P(=O)(OR)3), phosphite (P(OR)s), phosphonate (RP(=O)(OR)z), phosphinate (R2P(=O)(OR)), phosphine oxide (R3P(=O)), or phosphine (R3P), wherein each R in the may be the same or different, provided that at least one R is an aromatic group; a monomeric or oligomeric compound having at least one phosphorous- nitrogen bond; or a combination thereof.

[0110] Aspect 9a. The polycarbonate composition of any one of the preceding aspects, wherein the organophosphorous flame retardant comprises: ce of G¹ is independently a C1-30 hydrocarbyl; each occurrence of G² is independently a C1-30 hydrocarbyl or hydrocarbyloxy; each X is independently a bromine or chlorine; R¹⁶, R¹⁷, R¹⁸, and R¹⁹ are each independently C1-8 alkyl, C5.6 cycloalkyl, C'e-zo aryl, or C7-12 arylalkylene, each optionally substituted by C1-12 alkyl, preferably by C1-4 alkyl; X is a mono- or poly-nuclear aromatic Ce-30 moiety or a linear or branched C2-30 aliphatic radical, each optionally OH-substituted and optionally comprising up to 8 ether bonds; at least one of R¹⁶, R¹⁷, R¹⁸, R¹⁹, and X is an aromatic group; m is 0 to 4; and n is 1 to 30.

[0111] Aspect 9b. The polycarbonate composition of any one of the preceding aspects, wherein the organophosphorous flame retardant is a phosphazene of combination thereof, wherein wl is 3 to 10,000, w2 is 3 to 25, and each R^w is independently a C1-12 alkyl, C2-12 alkenyl, C1-12 alkoxy, C6-12 aryl, C6-12 aryloxy, or polyoxy(Ci-6 alkylene) group.

[0112] Aspect 10. The polycarbonate composition of any one of the preceding aspects, wherein the mineral filler comprises mica, clay, feldspar, quartz, quartzite, perlite, tripoli, diatomaceous earth, aluminum silicate, synthetic calcium silicate, fused silica, fumed silica, sand, boron-nitride powder, boron-silicate powder, calcium sulfate, calcium carbonates, talc, wollastonite, or a combination thereof.

[0113] Aspect 11. The polycarbonate composition of any one of the preceding aspects, wherein the additive comprises an antioxidant, a heat stabilizer, a light stabilizer, an ultraviolet light stabilizer, a plasticizer, a lubricant, a mold release agent, an antistatic agent, a colorant, a surface effect additive, a radiation stabilizer, an anti-drip agent, or a combination thereof.

[0114] Aspect 12. The polycarbonate composition of any one of the preceding aspects, wherein the bromine-containing polycarbonate copolymer comprises first carbonate repeating units derived from bisphenol-A and second repeating brominated carbonate units derived from 2,2',6,6'-tetrabromo-4,4'- isopropylidenediphenol.

[0115] Aspect 12a. The polycarbonate composition of any one of the preceding aspects, wherein the bromine-containing polycarbonate copolymer comprises 10 to 50 wt%, 15 to 40 wt%, 20 to 30 wt%, or 24 to 27.5 wt% bromine content, each based on the weight of the bromine-containing polycarbonate.

[0116] Aspect 13a. The polycarbonate composition of any one of the preceding aspects, comprising 35 to 70 wt% of a homopolycarbonate; 10 to 25 wt% of a bromine-containing polycarbonate copolymer; 10 to 60 wt% of a poly(carbonate-siloxane), present in an amount effective to provide 1 to 10 wt% of total siloxane, based on the total weight of the polycarbonate composition; 4 to 20 wt% of glass fiber; 1 to 10 wt% of milled glass; and optionally, 1 to 5 wt% of an organophosphorous flame retardant in amount effective to provide up to 1.5 wt% of phosphorous, based on the total weight of the polycarbonate composition, wherein the amount of homopolycarbonate, bromine-containing polycarbonate copolymer, poly(carbonate-siloxane), glass-containing reinforcing agent, optional mineral filler, optional organophosphorous flame retardant, and optional additive total 100 wt%.

[0117] Aspect 13b. The polycarbonate composition of any one of the preceding aspects, comprising the polycarbonate composition may include 35 to 70 wt% of a combination of poly(phthalate- carbonate) and optionally, a homopolycarbonate; 10 to 25 wt% of a bromine- containing polycarbonate copolymer; 10 to 60 wt% of a poly(carbonate-siloxane), present in an amount effective to provide 1 to 10 wt% of total siloxane, based on the total weight of the polycarbonate composition; 4 to 20 wt% of glass fiber; 1 to 10 wt% of milled glass; and optionally, 1 to 5 wt% of an organophosphorous flame retardant in amount effective to provide up to 1.5 wt% of phosphorous, based on the total weight of the polycarbonate composition; wherein the amount of poly(phthalate-carbonate, optional homopolycarbonate, brominecontaining polycarbonate copolymer, poly(carbonate-siloxane), glass-containing reinforcing agent, optional mineral filler, optional organophosphorous flame retardant, and optional additive total 100 wt%.

[0118] Aspect 14. An article, comprising the polycarbonate composition of any one of the preceding aspects, preferably wherein the article is a railway component, preferably an interior railway component, more preferably wherein the article comprises a seat component, an extruded interior cladding, a molded interior cladding, a side wall, a front wall, an end wall, a partition, a room divider, a flap, a box, a hood, a louvre, a ceiling panel, a table tray, a head rest, a privacy divider, a center console, an arm rest, a leg rest, a food tray, an end bay, a shroud, a kick panel, a foot well, literature pocket, a monitor, a bezel, a line replaceable unit, a foot bar, a luggage rack, a luggage container, a luggage compartment, a floor composite, a wall composite, an air duct, a strip, a device for passenger information, a window frame, an interior lining, an interior vertical surface, an interior door, a lining for an internal door, a lining for an external door, an interior horizontal surface, an electrical component, or a lighting component.

[0119] Aspect 15. A method for forming the article of aspect 14, the method comprising molding, casting, or extruding the polycarbonate composition.

[0120] The compositions, methods, and articles may alternatively comprise, consist of, or consist essentially of, any appropriate materials, steps, or components herein disclosed. The compositions, methods, and articles may additionally, or alternatively, be formulated so as to be devoid, or substantially free, of any materials (or species), steps, or components, which are otherwise not necessary to the achievement of the function or objectives of the compositions, methods, and articles.

[0121] All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other (e.g., ranges of “up to 25 wt%, or, more specifically, 5 wt% to 20 wt%”, is inclusive of the endpoints and all intermediate values of the ranges of “5 wt% to 25 wt%,” etc.). “Combinations” is inclusive of blends, mixtures, alloys, reaction products, and the like. The terms “first,” “second,” and the like, do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The terms “a” and “an” and “the” do not denote a limitation of quantity and are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. “Or” means “and/or” unless clearly stated otherwise. Reference throughout the specification to “some aspects”, “one or more aspects”, and so forth, means that a particular element described in connection with the aspect is included in at least one aspect described herein, and may or may not be present in other aspects. In addition, it is to be understood that the described elements may be combined in any suitable manner in the various aspects. A “combination thereof’ is open and includes any combination comprising at least one of the listed components or properties optionally together with a like or equivalent component or property not listed

[0122] Unless specified to the contrary herein, all test standards are the most recent standard in effect as of the filing date of this application, or, if priority is claimed, the filing date of the earliest priority application in which the test standard appears.

[0123] Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art to which this application belongs. All cited patents, patent applications, and other references are incorporated herein by reference in their entirety. However, if a term in the present application contradicts or conflicts with a term in the incorporated reference, the term from the present application takes precedence over the conflicting term from the incorporated reference.

[0124] Compounds are described using standard nomenclature. For example, any position not substituted by any indicated group is understood to have its valency filled by a bond as indicated, or a hydrogen atom. A dash ("-") that is not between two letters or symbols is used to indicate a point of attachment for a substituent. For example, -CHO is attached through carbon of the carbonyl group.

[0125] The term "alkyl" means a branched or straight chain, unsaturated aliphatic hydrocarbon group, e.g., methyl, ethyl, n-propyl, i-propyl, n-butyl, s-butyl, t-butyl, n-pentyl, s-pentyl, and n- and s- hexyl. “Alkenyl” means a straight or branched chain, monovalent hydrocarbon group having at least one carbon-carbon double bond (e.g., ethenyl (-HC=CH2)). “Alkoxy” means an alkyl group that is linked via an oxygen (i.e., alkyl-O-), for example methoxy, ethoxy, and sec -butyloxy groups. "Alkylene" means a straight or branched chain, saturated, divalent aliphatic hydrocarbon group (e.g., methylene (-CH2-) or, propylene (-(CHz -)). “Cycloalkylene” means a divalent cyclic alkylene group, -C_nH2_n-x, wherein x is the number of hydrogens replaced by cyclization(s). “Cycloalkenyl” means a monovalent group having one or more rings and one or more carbon-carbon double bonds in the ring, wherein all ring members are carbon (e.g., cyclopentyl and cyclohexyl). "Aryl" means an aromatic hydrocarbon group containing the specified number of carbon atoms, such as phenyl, tropone, indanyl, or naphthyl. “Arylene” means a divalent aryl group. “Alkylaryl” means an aryl group substituted with an alkyl group. “Arylalkyl” means an alkyl group substituted with an aryl group (e.g., benzyl). The prefix "halo" means a group or compound including one more of a fluoro, chloro, bromo, or iodo substituent. A combination of different halo groups (e.g., bromo and fluoro) may be present. The prefix “hetero” means that the compound or group includes at least one ring member that is a heteroatom (e.g., 1, 2, or 3 heteroatom(s)), wherein the heteroatom(s) is each independently N, O, S, Si, or P. “Substituted” means that the compound or group is substituted with at least one (e.g., 1, 2, 3, or 4) substituent instead of at least one (e.g., 1, 2, 3, or 4) hydrogen atom that may each independently be a C1-9 alkoxy, a C1-9 haloalkoxy, a nitro (-NO2), a cyano (- CN), a C1-6 alkyl sulfonyl (-S(=O)2-alkyl), a Ce-12 aryl sulfonyl (-S(=O)2-aryl)a thiol (-SH), a thiocyano (- SCN), a tosyl (CH3C6H4SO2-), a C3-12 cycloalkyl, a C2-12 alkenyl, a C5-12 cycloalkenyl, a Ce-12 aryl, a C7-13 arylalkylene, a C4-12 heterocycloalkyl, a C3-12 heteroaryl, or a combination thereof, provided that the substituted atom’s normal valence is not exceeded.

[0126] While particular aspects have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are or may be presently unforeseen may arise to applicants or others skilled in the art. Accordingly, the appended claims as filed and as they may be amended are intended to embrace all such alternatives, modifications variations, improvements, and substantial equivalents.

Claims

CLAIMS What is claimed is:

1. A polycarbonate composition, comprising:

10 to 80 wt%, or 20 to 75 wt%, or 35 to 70 wt% of a homopolycarbonate, a poly(phthalate- carbonate), or a combination thereof;

10 to 30 wt%, or 10 to 25 wt% of a bromine-containing polycarbonate copolymer;

5 to 60 wt%, or 10 to 60 wt% of a poly(carbonate-siloxane), present in an amount effective to provide 1 to 10 wt% of total siloxane, based on the total weight of the polycarbonate composition;

5 to 30 wt%, or 5 to 25 wt% of a glass-containing reinforcing agent; optionally, up to 10 wt% of a mineral filler, preferably wherein the mineral filler comprises talc, kaolin, calcium silicate, calcinated kaolin, calcium carbonate, wollastonite, or a combination thereof; optionally, an organophosphorous flame retardant in amount effective to provide up to 1.5 wt% of phosphorous, based on the total weight of the polycarbonate composition; and optionally, up to 10 wt% of an additive, wherein the amount of homopolycarbonate, poly(phthalate-carbonate, bromine-containing polycarbonate copolymer, poly(carbonate-siloxane), glass-containing reinforcing agent, optional mineral filler, optional organophosphorous flame retardant, and optional additive total 100 wt%.

2. The polycarbonate composition of claim 1, wherein the polycarbonate composition does not further comprise a poly etherimide.

3. The polycarbonate composition of claim 1 or 2, wherein a molded sample of the composition has: a smoke density after 4 minutes (DS-4) of 300 or less, measured in accordance with ISO 5659-2 on a 3 mm thick plaque at 50 kW/m²; an integral of smoke density as a function of time after 4 minutes (VOF4) of 600 or less, measured in accordance with ISO 5659-2 on a 3 mm thick plaque at 50 kW/m²; a maximum average heat release (MAHRE) of 90 kW/m² or less, measured in accordance with ISO 5660-1 on a 3 mm thick plaque at 50 kW/m²; a critical heat flux at extinguishment (CFE) of 20 kW/m² or greater, measured in accordance with ISO 5658-2 on a 3 mm thick plaque; or a combination thereof.

4. The polycarbonate composition of any one of the preceding claims, wherein the poly(carbonate-siloxane) comprises a poly(carbonate-siloxane) copolymer comprising 10 wt% or less of siloxane content, a poly(carbonate-siloxane) copolymer comprising greater than 10 to less than 30 wt% of siloxane content, a poly(carbonate-siloxane) copolymer comprising 30 to 70 wt% of siloxane content, or a combination thereof, ' wherein each amount is based on total weight of the poly(carbonate-siloxane) copolymer.

5. The polycarbonate composition of any one of the preceding claims, wherein the glasscontaining reinforcing agent is glass fiber, milled glass, glass bead, glass flake, or a combination thereof, preferably wherein the glass-containing reinforcing agent is glass fiber, milled glass, or a combination thereof.

6. The polycarbonate composition of any one of the preceding claims, wherein the glasscontaining reinforcing agent comprises:

4 to 20 wt% of glass fiber; and

1 to 10 wt% of milled glass, wherein each amount is based on the total weight of the polycarbonate composition.

7. The polycarbonate composition of any one of the preceding claims, wherein the organophosphorous flame retardant comprises a C3.30 aromatic group and a phosphate group, phosphite group, phosphonate group, phosphinate group, phosphine oxide group, phosphine group, phosphazene, or a combination comprising at least one of the foregoing phosphorus-containing groups.

8. The polycarbonate composition of any one of the preceding claims, wherein the organophosphorous flame retardant comprises: a monomeric or oligomeric phosphate (P(=O)(OR)3), phosphite (P(OR)s), phosphonate (RP(=O)(OR)Z), phosphinate (R₂P(=O)(OR)), phosphine oxide (R3P(=O)), or phosphine (R3P), wherein each R in the may be the same or different, provided that at least one R is an aromatic group; a monomeric or oligomeric compound having at least one phosphorous-nitrogen bond; or a combination thereof.

9. The polycarbonate composition of any one of the preceding claims, wherein the organophosphorous flame retardant comprises: a combination thereof, wherein, each occurrence of G¹ is independently a C1-30 hydrocarbyl; each occurrence of G² is independently a C1-30 hydrocarbyl or hydrocarbyloxy; each X is independently a bromine or chlorine;

R¹⁶ _R17 _R18 _{and R}19 are each independently Ci-s alkyl, C5-6 cycloalkyl, C6-20 aryl, or C7-12 arylalkylene, each optionally substituted by C1-12 alkyl, preferably by C1-4 alkyl;

X is a mono- or poly-nuclear aromatic C6-30 moiety or a linear or branched C2-30 aliphatic radical, each optionally OH-substituted and optionally comprising up to 8 ether bonds; at least one of R¹⁶, R¹⁷, R¹⁸, R¹⁹, and X is an aromatic group; m is 0 to 4; and n is 1 to 30.

10. The polycarbonate composition of any one of the preceding claims, wherein the mineral filler comprises mica, clay, feldspar, quartz, quartzite, perlite, tripoli, diatomaceous earth, aluminum silicate, synthetic calcium silicate, fused silica, fumed silica, sand, boron-nitride powder, boron-silicate powder, calcium sulfate, calcium carbonates, talc, wollastonite, or a combination thereof.

11. The polycarbonate composition of any one of the preceding claims, wherein the brominecontaining polycarbonate copolymer comprises first carbonate repeating units derived from bisphenol-A and second repeating brominated carbonate units derived from 2,2',6,6'-tetrabromo-4,4'- isopropylidenediphenol.

12. The polycarbonate composition of any one of the preceding claims, comprising:

35 to 70 wt% of a combination of poly(phthalate-carbonate) and optionally, a homopolyc arbonate ;

10 to 25 wt% of a bromine-containing polycarbonate copolymer;

10 to 60 wt% of a poly(carbonate-siloxane), present in an amount effective to provide 1 to 10 wt% of total siloxane, based on the total weight of the polycarbonate composition;

4 to 20 wt% of glass fiber; 1 to 10 wt% of milled glass; and optionally, 1 to 5 wt% of an organophosphorous flame retardant in amount effective to provide up to 1.5 wt% of phosphorous, based on the total weight of the polycarbonate composition; wherein the amount of poly(phthalate-carbonate, optional homopolycarbonate, brominecontaining polycarbonate copolymer, poly(carbonate-siloxane), glass-containing reinforcing agent, optional mineral filler, optional organophosphorous flame retardant, and optional additive total 100 wt%.

13. The polycarbonate composition of any one of the preceding claims, comprising:

35 to 70 wt% of a homopolycarbonate;

10 to 25 wt% of a bromine-containing polycarbonate copolymer;

4 to 20 wt% of glass fiber; 1 to 10 wt% of milled glass; and optionally, 1 to 5 wt% of an organophosphorous flame retardant in amount effective to provide up to 1.5 wt% of phosphorous, based on the total weight of the polycarbonate composition, wherein the amount of homopolycarbonate, bromine-containing polycarbonate copolymer, poly(carbonate-siloxane), glass-containing reinforcing agent, optional mineral filler, optional organophosphorous flame retardant, and optional additive total 100 wt%.

14. An article, comprising the polycarbonate composition of any one of the preceding claims, preferably wherein the article is a railway component, preferably an interior railway component, more preferably wherein the article comprises a seat component, an extruded interior cladding, a molded interior cladding, a side wall, a front wall, an end wall, a partition, a room divider, a flap, a box, a hood, a louvre, a ceiling panel, a table tray, a head rest, a privacy divider, a center console, an arm rest, a leg rest, a food tray, an end bay, a shroud, a kick panel, a foot well, literature pocket, a monitor, a bezel, a line replaceable unit, a foot bar, a luggage rack, a luggage container, a luggage compartment, a floor composite, a wall composite, an air duct, a strip, a device for passenger information, a window frame, an interior lining, an interior vertical surface, an interior door, a lining for an internal door, a lining for an external door, an interior horizontal surface, an electrical component, or a lighting component.

15. A method for forming the article of claim 14, the method comprising molding, casting, or extruding the polycarbonate composition.